LED Light Engine Tapered Fitting Heat Sink Assembly
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Solution Overview
Problem
Conventional LED light sources face challenges in thermal management due to weak radiative heat transfer at lower operating temperatures, requiring enhanced convective and conductive heat transfer methods, which can be complex and costly.
Innovation Solution
A tapered fitting mechanism between the LED light engine substrate and the heat sink provides a strong retention force through compression and static friction, facilitating effective heat transfer without the need for adhesives or solder, using a thermally conductive substrate material and optional microstructures for enhanced retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heat sinks with large surface area are used for LED thermal management, then heat dissipation efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the light engine substrate and heat sink into a single integrated assembly. The substrate serves dual functions as both the LED mounting platform and the heat dissipation structure, eliminating the need for separate heat sink components while maintaining effective thermal management through the substrate's inherent thermal conductivity and geometric design.
Solution Approach 2:
The light engine substrate is designed to perform multiple functions simultaneously: electrical connection for LED operation, mechanical support for LED devices, and thermal conduction for heat dissipation. This multi-functional design replaces traditional separate components (substrate + heat sink + retention mechanisms) with a single universal element.
2Strength
If additional retention components are added to secure LED light engine in heat sink, then mechanical retention is improved, but manufacturing complexity and assembly steps increase
Solution Approach 1:
The retention function is merged into the substrate-heat sink interface design itself. The tapered geometric configuration of the substrate creates inherent mechanical retention through friction and geometric interlocking with the heat sink receptacle, eliminating the need for separate retention components such as screws, clips, or adhesives.
Solution Approach 2:
The tapered substrate design provides self-retention through its own geometric features. When inserted into the heat sink receptacle, the tapered shape automatically creates frictional engagement and mechanical locking without requiring external retention mechanisms, enabling simple drop-in assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures efficient heat dissipation and reliable retention of the LED light engine within the heat sink, reducing manufacturing complexity and costs while maintaining the LED devices at optimal operating temperatures.
Implementation Method 1
The LED light engine substrate and the mating receptacle of the heat sink define a tapered fitting by which the LED light engine is retained in the mating receptacle of the heat sink
Implementation Method 2
The LED light engine substrate and the mating receptacle of the heat sink define a tapered fitting by which the LED light engine is retained in the mating receptacle of the heat sink
Implementation Method 3
using a thermally conductive substrate material and optimized taper angles for efficient heat dissipation
Implementation Method 4
At these low operating temperatures, the radiative heat transfer pathway to the ambient is weak compared with that of conventional light sources, so that convective and conductive heat transfer to ambient typically dominate over radiation
Implementation Method 5
the radiative heat transfer pathway to the ambient is weak compared with that of conventional light sources, so that convective and conductive heat transfer to ambient typically dominate over radiation
Data Source
AI summary
According to a first embodiment, a light emitting diode (LED) light engine is described. The light emitting diode includes one or more LED devices disposed on a front side of an LED light engine substrate. A heat sink having a mating receptacle for the LED light engine is also provided. The LED light engine substrate and the mating receptacle of the heat sink define a tapered fitting by which the LED light engine is retained in the mating receptacle of the heat sink.